MEP-6T

Operations Manual
(Manual Electrical Press – 6 Ton)

Rev B 1/99

1
INTRODUCTION

About This Manual

This manual contains the installation, safety, operation, and maintenance procedures for the 6 ton Manual Electric
Press (MEP-6T).

SAFETY
The MEP-6T is designed to comply with the latest safety standards required by OSHA, NFPA-79, CSA, and CE.
It has been evaluated by a third party Inspection Agent for SEMI-S2 compliance.

Lock Out/ Tag Out

CE Required

The main power disconnect switch is provided in the rear panel of the machine and is clearly marked. When it is
in the “ON” position, it is mechanically interlocked to prevent the access door from being opened. In addition to
the mechanical interlock, the door is equipped with a keyed lock.

! Eye Protection

CE Required

Eye protection should be worn at all times when operating or servicing this machine. In the event a connector is
crushed during the pressing operation, pieces of the connector could become airborne. Please note: the laser
sensor does not require eye protection use.

2
Safety Covers / Guards

CE Required

All safety guards must be in place before operating the press. This includes all sheet metal and Lexan panels
around the machine.

Laser Sensor

CE Required
The press is equipped with a Class II laser sensor model FSL manufactured by Keyence. It emits a visible red
laser beam at 670nm, and 3 mw maximum power. The FDA registration number for the laser is 922328-00. The
laser beam is not directly viewable during normal operation due to the mounting position. No special eye
protection is required.
No eye protection required under normal operating condition. Reflected laser may be dangerous.
CAUTION: Use of controls or adjustments or performance of procedures other than those specified herein may
result in hazardous radiation exposure.
The FSL laser device is equipped with an interlock that prevents laser emission if the fiber beam delivery cable is
disconnected.

Lockout label Safety Cover and Eye protection

Guard labels label location

(MEP-6T viewed from front)

Laser Warning
Electrical hazard label location
(MEP-6T viewed from rear) labels

Note: The above photos illustrate typical locations for the safety labels on the MEP-6T. Safety cover and guard labels
are also located on both side covers and on the rear panel.

3
Emergency Machine Off (EMO) / ESTOP
The Emergency Machine Off / Emergency Stop switches are mounted at the left and right corners of the table at
the front of the press. They are clearly marked. When pressed, the switch latches in the pressed state and must be
twisted to release. The EMO circuit is a hardware (dry contact) based latching circuit that does not reset when the
EMO switch is released.
All voltage that is above 24VDC and external to the control cabinet (with the exception of the computer monitor)
is removed when the EMO is pressed.
The EMO circuit is energized by an output from the computer when all safety conditions are met. The conditions
which must be met are: (please refer to the schematic, 197E0900, “Power & Control” sheet)
1) Acroloop Servo Controller Watchdog Signal True - signal is false if the controller detects a problem
2) Acroloop Servo Controller PLC Output – the servo controller has an internal program that monitors servo
operation and drops the EMO circuit if a problem is detected
3) Motor Overload Relay – This is heater based motor overload detection device that monitors the motor current
draw and trips if the motor pulls too much current for too long a time. It automatically resets after a cooling
period of approximately 2 minutes.

Two-Hand Start Switches

The Two-Hand Start Switches are the primary operator safety devices. They are located below the table on the
right and left sides of the keyboard drawer. Zero force is required for actuation due to the optical switch design.
Each switch is wired to separate input, allowing the computer to monitor them for both actuation and release.
Before a cycle can be initiated both switches must be clear, then actuated within ½ second of each other. If either
switch is released during a cycle all motion is immediately halted.
During normal operation, messages displayed on the screen can be acknowledged and cleared by touching either
of the buttons.

Light Curtains
The light curtain is a secondary operator safety device. When the curtain is blocked, a relay in the Light Curtain
Control box is de-energized (please refer to the schematic, 197E0900, “Power & Control” sheet, relay CR7). A
normally open contact from this relay drops the latched safety circuit. This safety circuit disables the motor
amplifier and removes power from the motor. The motor can only be re-energized after the light curtain is
cleared and the computer resets the safety circuit. If there is a failure in the computer, such as a lockup, the safety
circuit cannot be re-energized. See Light Curtain Override Key Switch section below for important light curtain
operational information.

Light Curtain Override Key Switch

The key switch is used to inhibit normal light curtain operation (please refer to the schematic, 197E0900, “Power
& Control” sheet). This allows the head to be moved while the light curtain is blocked when in maintenance
mode only. Normal operation is prohibited when the key is in the “BYPASS” position.
In addition to the security of the key bypass and software prohibiting normal operation while in bypass mode, all
maintenance functions are protected by password.

4
Pneumatic System
The pneumatic system is provided strictly for the air bearing that floats the head for side to side adjustment.
There are no special precautions required when for pneumatic system considerations.

Caster Wheels
The machine is mounted on four swivel casters. The rear two casters are lockable. Two people are required when
moving the machine as it is heavy.

Seismic Restraints
Protection from unwanted motion during an earthquake can be achieved by bolting the frame to the floor. This
can be done in many ways, two of which are described here.
1) Drill holes through the lower frame tube on the right and left sides of the machine. Secure Eye-Bolts to the
holes. Anchor similar Eye-Bolts into the floor below the machine. Secure the machine to the floor using
chain or cable.
2) Fabricate steel angle plates to bolt to the lower frame tube at the left and right sides of the machine. Anchor
the angle plates to the floor.
A seismic restraint kit is available from ASG on request.

Frame Construction and Weight Distribution

The frame is constructed of tubular steel welded together as shown below.

5
INSTALLATION
This section describes the installation steps and requirements.

Uncrating
The press, computer, monitor, leveling feet, and other removed parts are shipped on one pallet and is shrink-
wrapped for protection. Remove the shrink-wrap and unpack the monitor, computer and other shipped parts.
Remove Press from pallet by unbolting holddown bolts on four legs and lifting up several inches with a forklift
(using 2x4 wood between underside of Top Horizontal Frame Plates, P/N 209A0210 and fork lift blades).

Initial Assembly
1. Using the four supplied bolts (3/16” – 16 X ¾” socket head screws and 3/8” flat washers per wheel),
install the four Caster wheels to bottom of Press with two steerable wheels on front of Press.
2. Install customer supplied 4-conductor power cord (220VAC 3∅ 20 Amp) thru 90 deg. Sealtite connector
feedthru to Master Power Switch in back of MEP-6T. Note: The press can use either 220 or 208 VAC,
but the transformer behind the panel in the lower front must be tapped appropriately. This transformer is
used to generate 120 VAC for the computer and other devices.
3. Install customer supplied Industrial Air line to ‘Quik Disconnect’ input on lower back side of Press.
Verify that shop air input has a minimum of 80 P.S.I. to MEP-6T Air Regulator.
4. Reattach Monitor Stand using the Pivot Bolt (P/N 91259A724) and extension arm (P/N 197A0612) to
attach to the installed mount block (P/N 197A0610).
5. Reinstall Barcode Reader and Touch Pad on Monitor Stand.
6. Install Touch Screen Monitor on Stand using 2 lockdown brackets (supplied) on monitor base. Reattach
110Vac power cord, video cord and touch screen control cable to monitor back.
7. Remove Press Head lockdown brackets, if installed.
8. Bring Computer to backside of Press and open up computer chassis. Install P.C. Card cage, complete
with both Acroloop cards into the computer chassis. Reinstall computer power cord and Monitor video
cable to backside of computer. Set down computer into a vertical position and snugged into lower
positioning blocks located on Electrical chassis floor. Reinstall upper locating bracket (upper computer
support).
9. Power up Press by turning on Master Power Switch. Verify that computer comes ‘up’. If proper
supervisor data (specific customer assignments) is installed in computer database, Press should be fully
operational. Log on. initially, using “Aaron Arnold” with password “1”. Note: Adminisrator (Customer /
Owner) should have changed this initial logon name from Aaron Arnold to ‘Administrator’ with
appropriate password.

6
Facilities Labeling
The electrical and pneumatic requirements are given on the label on the left side of the machine

Electric Supply Circuit

Electrical supply circuit must be 220 VAC or 208 VAC, 3 phase, 4 wire service. It must be protected by a breaker
rated for at least 10,000 IAC.
Important Note: The press is shipped with an internal step down transformer taped for 220VAC. If your
service is 208 VAC, the transformer must be re-tapped. The transformer is located behind the front kick
panel. The instructions are attached to the transformer cover. Check the 110VAC circuit for proper
voltage before operating the press.

Pneumatic Supply
The pneumatic supply must be connected to the port provided at the lower left corner of the press. Any pressure
above 80 PSI is acceptable. Compressed air is used only for the head positioning air bearing. Air consumption is
minimal.

7
 PRESS OVERVIEW
This section introduces the MEP-6T, Manual Electric Press. A brief review of the purpose, capabilities, options,
and layout is given.

Overall Height
70”

Overall width
Overall Depth
Overall width including printer
36”
38” 50”

Purpose
The MEP-6T all electric servo press was designed for two primary purposes. First, to satisfy the increasing need
for controlled quality pressing of connectors on today’s complex circuit boards. As the density of connectors
increases they become more fragile. At the same time circuit boards have become more complex, susceptible to
damage, and costly. This trend will undoubtedly continue and accelerate as interconnect PCB’s continue move
from simple passive elements to more complex devices with surface mount devices, and devices buried in the
inner layers. In recent years, backpanel assembly shops have had to dramatically increase their process
sophistication. It has become obvious that the old methods of “slamming” the connectors into the board are no
longer acceptable. The MEP-6T, being an electric servo driven press, precisely controls the force and speed of
each pressing cycle. In addition to control, quality feedback in the form of SPC (Statistical Process Control)
analysis, display, and reports is available for the first time. Valuable data can now be captured and analyzed to
improve the entire interconnect process.
The second purpose is to improve the efficiency of the pressing process. The manual techniques traditionally used
for pressing connectors have been very labor intensive, unsafe, and ergonomically unacceptable. The result is that
the throughput and quality have been operator dependant, which inevitably produces variable results. The electric
servo press improves throughput while yielding more consistent computer controlled results with quality data
feedback.
Thus, the dual purpose of this press meets the needs of the assembly shop and the end customer simultaneously.

Capabilities
The MEP-6T delivers a controlled force of up to 6 tons (12,000 lbs) through a 10” long x 1-1/2 wide “flat rock”
head. The Z axis travel is 5”, and the “up” position can be programmed for any desired clearance above the tool
before pressing. This improves efficiency by limiting the stroke travel per cycle. It can also be very convenient
to use the press head as a tool support for unstable tool/connector situations.

8
The pressing process can be controlled in one of five ways.
1) FIXED FORCE - A connector can be pressed to a set force such as 1000 pounds. This is the common
technique used by hydraulic and pneumatic presses. It is the least sophisticated method available, and is the
most likely to damage the PCB or connector.
2) FIXED FORCE PER PIN - A connector can be pressed to a set force per pin, such as 30 pounds per pin.
This is slightly better than the first method because it recognizes that the force applied should be proportional
to the number of pins being pressed. It cannot, however, compensate for normal variations in required force
per pin for different connectors, in different positions, in different boards.
3) PRESS TO HEIGHT – A connector can be pressed to within a programmed distance short of seating on the
board surface. This is the gentlest process possible because it exerts only enough force to press the pins into
the board. No excess force is pressed into the connector plastic or the board. This sophisticated technique is
made possible by the control available using an electric servo press head and a rigid press structure. In order
for press to height to be accurate, the board thickness must be precisely known. This can be done using the
thickness measurement probe and sequence provided.
4) (PARS) – PERCENT ABOVE RANGE SAMPLE – A connector can be pressed with force that is
proportional to the actual resisting force detected during the pressing cycle. We call this Percent Above
Range Sample or PARS. In this technique, the connector’s resisting force while pressing is sampled and
averaged over a distance range before seating to the board surface. The final force percent added assures
complete seating of the connector. This is the most widely used technique because it limits the stress to the
assembly, but does not require great accuracy for board thickness measurement.
5) FORCE GRADIENT – Monitors the rate of change of force to distance. This method is used for robust
connectors that need to be seated against the board surface. Generally, the force vs distance plot will make a
steep upturn as the connector contacts the board surface. The connector stops moving so the force rises
quickly. A minimum angle is specified for the upturn which corresponds to how solidly the connector is
pressed against the board.
The PCB size limit is 24” X 36”. The structure opening width is 30”, and press head can be manually move from
side to side to access the edges of wide boards.
The program for pressing is a simple table of connector types and positions. Each pressing cycle, called a profile,
is precisely defined by the user to control force, speed, and distance as the connector is pressed. This highly
flexible technique allows a virtually unlimited variety of pressing options to satisfy the needs of present and future
connectors. Data describing the connectors, tools, PCB, and pressing profile are stored in databases that can be
modified either on or off line.
Many useful features and utilities are provided for maintenance. This includes on screen display of all machine
inputs, and access to force all outputs.

Options
Touch screen SVGA monitor
The touch screen monitor provides a very convenient operator interface. It allows the operator to quickly respond
to messages without diverting their attention from the screen.

Board Thickness Measurement

Board thickness measurement facilitates the press to height technique by measuring the actual thickness of the
PCB before the pressing cycle starts. If the board thickness is not measured, the program uses a nominal thickness
in height calculations.

9
SPC (Statistical Process Control)
The SPC option provides real time data on the pressing force on each connector. Charts can be viewed live on
screen, or recalled later for review. The supporting raw data is available for local or network access.
Configurable reports are also available. The charts and data can be shared with the end user to increase their
confidence in the quality of the pressing process.

Bar Code Reader

The bar code reader option allows PCB serial numbers to be quickly entered for tracking purposes. Stored data
and printed reports include the scanned serial number.
Pressing tools can also identified by bar code for efficient and accurate control. A setup check box allows tool
identification to be turned on and off.

Laser pointer
The laser pointer is an aid to correctly positioning the PCB under the press head. Proper positioning can be
achieved by providing a target on the top of the pressing tool, which the operator aligns with the laser spot.
The active laser pointer / sensor provides the same visual feedback, but also uses an integral sensor to confirm the
presence of a tool via a reflective target on the top of the tool. The pressing cycle is inhibited if no tool is
detected by the laser. This provides an added level of safety and quality.

Light curtain - CE certified

The light curtain is mounted across the front access area of the press. If it is obstructed, the pressing process is
inhibited. A bypass key allows access to maintenance personnel when needed. This safety device is a secondary
backup to the two-hand anti-tie-down switches that are standard.

Digital color camera

One of the methods of programming a PCB uses a digital photograph. The image is used to guide the operator
through the desired pressing sequence. The digital camera is used to acquire these images.

Color printer
SPC charts, reports, and screen captures can be printed out on the color printer. A printer shelf, which can be
mounted on either side of the press, is provided with this option.

10
Machine Specific Configuration

The configuration of the machine can be viewed by double clicking the left mouse button on the main screen.
The machine attributes are given as shown here. The status of the available options available is also shown.

Layout

The press is a freestanding steel famed machine mounted on four swivel wheels. The pressing forces are
contained within an “H frame structure” constructed of 1” thick steel plates. The width between the vertical
support plates is 30”.
The press head assembly is mounted on the top of the structure. It can be manually adjusted to any point between
the left and right vertical supports.
The electrical components are located in locked and electrically interlocked cabinet in the rear of the machine.
The computer is also in the rear cabinet. The light curtain control DC power supplies are behind the panel in the
front below the table. The panel must be removed to access this area.

11
OPERATION

Getting Started
This startup procedure assumes all necessary information has been entered in the Tool Database, Connector
Database, Profile Database, and Press Data File. See the programming section for details in entering data in these
files.

Powering Up

Main Power
Switch

! CAUTION: THE REAR DOOR MUST BE FULLY CLOSED AND LOCKED BEFORE TURNING POWER
ON. BE SURE ALL SAFETY COVERS ARE IN PLACE, AND PERSONNEL ARE CLEAR OF THE
MACHINE BEFORE STARTING THE MACHINE.

The main power disconnect is mounted in the panel at the rear of the machine. Turning the switch to the “OFF”
position disconnects all three phases of the incoming power. It can be locked out for safety and security proposes.
Turn it to the “ON” position to start the machine.

12
Operator Interface
All selections on the computer monitor can be made by either touching the screen with a finger (if the touch
screen option is included) or by pointing and left clicking with the mouse. Alphanumeric entries can be entered
by the keyboard or by touching the screen buttons provided. Note that a drop of moisture on the face of the touch
screen will prevent normal operation until it is removed.

Logging On
When the boot process is complete, the startup screen is displayed. The only option available on startup is

the “OPERATOR” icon. Touch the icon with your finger or left click with the mouse pointer.
Select your name from the list displayed (if your name does not appear on the list, you must see the system
ADMINISRATOR to add it). Enter your password and press “OK”.

13
User Access

User access is controlled by 4 levels of passwords. To enter a new user, an individual with an administrator level
must log in and press the “User Access” button pictured above. The new user access will be limited to not exceed
the level of the individual presently logged in. Fill in the first and last names, the password, and the options to
access. The Notes entry may be used for any purpose.
The “Temp Disqualify” selection allows a user name to stay in the computer but not be usable. It can be re-
enabled at a later time.

14
Selecting The Board
Press the “SELECT BOARD” button on the lower left area of the screen. Now select the board from the list
presented. Use the up and down arrow keys as needed to change pages.

Running The Board

Double click the “RUN” icon to start the pressing process.

The first screen displayed will depend on which options have been turned on in the Press Data Editor for the
current board. The requested information can be entered at this time, or press “Cancel” to enter it later. See the
“Start Pressing” section below for details on information requested before running a board.
The run screen will display showing a rendering of the PCB based on the input data on the left, a blank graph for
the pressing force and distance data on the right, and a series of buttons along the bottom. If an error message
regarding a missing data is displayed you must return to the editors to correct the problem. See the
“Programming” section below for details on information in the databases.

15
Run Screen Buttons
Depending on the access level of the person logged in, only some of the buttons may be available. The purposes
of the buttons from left to right are as follows.
“Z Up” - Used to raise the Z axis after a normal cycle is interrupted. An interruption can be caused automatically
by an error condition or manually by releasing the START buttons.
“Go To” - Used for random access to any connector on the PCB. Using the mouse pointer, left click on the
desired connector. The selected connector will be highlighted. Now press the “GO TO” button to select this
connector to be pressed next. No machine movement will occur. The sequence will continue from this point.
“Tools” - Used to access the tool information. Pressing this button will display a list of all the tools in the current
job. In User Mode, the next tool to be used can be picked form this list. See the Press Data Editor section below
for further explanation of modes of operation. This button may not be available to all user access levels.
“Run Screen” – Restores the normal run screen view after selection of one of the other available views such as
SPC.
“SPC” - Gives access to the SPC data screen. If SPC is not available, this button will be low lighted (grayed out).
If any SPC parameter goes out of control, the icon will flash with two red horizontal bars. See SPC section for
details on display and use of this feature.
“Offset” - Used to change the pressing height or graph alignment. The offset window allows a stored offset to be
changed for all connectors on the PCB, or only the current connector type. A check box selects between these
options. Offset is particularly useful in compensating for the many variables encountered when pressing to height.
The offset shown when this button is pressed corresponds the next connector to be pressed in the current sequence.
When changing an offset, verify the name of the connector in the upper right of the screen to avoid unexpected
results.

16
The Graph Offset changes the alignment of the displayed data to the graph X-axis. This is useful to correct

the display to align the upturn in the plot that occurs when the connector touches the board surface, with 0.000”.
This button may not be available for all users access levels.
“Profile Editor” - Used to enter a new pressing profile, or to modify the current profile at run time. See the
Editors section for details on usage. This button is not available for all user access levels.
“New Board” - Used to reset the sequence pointer to the first connector. The result is the same as touching
connector # 1 and pressing the “Go To” button. A prompt will be given to verify a return to the first connector is
desired.
“Exit” - Used to return to the main screen as displayed on startup. This is usually done at the completion of a
press run. From the main screen, a new PCB can be selected or the operator can log off. Logging off when
leaving the machine unattended will prevent unauthorized access.

17
“Performance” – The performance button is in the upper right corner of the screen. Pressing this button

displays process performance parameters. The Throughput parameters are self explanatory. The Profile Timing /
Errors section shows the number of seconds taken to press the last connector of each type. It also shows the
number of profile errors, types 1 through 5, that have occurred. The force monitor section shows the average
force over a distance range (this is the SPC distance range if available). It also shows the maximum force and the
height where it was measured.
“Diagnostics” – Pressing function key “F2” toggles diagnostics. The current state is shown at the bottom of the
screen. With diagnostics on, detailed information relating to the pressing process is shown in light gray on the
screen. The profile speed and transition points are shown, and the termination of each profile step is shown as “F”
for force or “H” for height. This data can be useful in understanding the profile path taken while pressing. It also
shows the update time for the force and height readings in milliseconds.
“Runtime Help” – “F1” displays runtime help. It gives a brief description of function keys available while in the
run screen.
“Data Collection” – Collects raw data and assigns the file a .PDC extension. The file is written to SPC path
(C:\MEP\SPC). This option is only effective if Diagnostics mode is active. To start Data Collection, press “F3”.
“Print Force vs Distance Graph” – Press “F4” to print the displayed Force vs Distance Graph.

18
On Screen PCB Rendering
The PCB rendering drawn on the screen shows the connector locations relative to each other and the board edges.
The board thickness measurement point is shown as a circle with an “M” inside. The rendering is a good check
for gross errors when running a new program for the first time.

It will be obvious for example if a connector is off the board, or if there is an interference.
The rendering is shown with the first connector to be pressed highlighted in blue. This will be either the board
thickness measurement (if the option is enabled) or the first connector in the sequence.
It also shows the pressing sequence by number and gives the connector name. To read the detailed information,
zoom in by double clicking the rendering using the left mouse button. You can step through the three zoom levels
by continuing to double click. Panning around the PCB is done by touching or pointing and left clicking, then
dragging in the direction to pan.

Start Pressing

The pressing process is started by pressing the two-hand buttons simultaneously. If further information is required
before running the board it will be requested at this time. There are four entries that will be requested if the
options have been selected in the Press Data Editor. Keep in mind that a combination of any, all, or none of these
will be prompted depending on the program being run. The information can be typed from the keyboard, entered
via the touch screen, or bar code scanned.

Connector Substitution – This feature allows for interchangeable connectors, typically from different
manufacturers, to be selected at runtime. If any connector on the currently selected board has an alternate and this
feature has been checked in the Press Data File editor (see the Connector and Press Data Editors for programming
of this feature), you will be prompted to make a selection. Pressing “enter” will select the default connector type.

PCB Verify – This feature requires verification of the “type” or “model” of the board being run. Ideally, the
board will be bar coded with this information, but typing it in will also work.

19
Serial Number – This feature requests the serial number for each board. Bar coding is the most convenient

method to use. For data options refer to the Press Data Editor below.

Tool ID – This feature requires the tool identification to be verified before pressing proceeds. It is a quality
confirmation that reduces the possibility of a mismatch between what the press expects and what the operator is
doing. The ID can be typed or scanned in.

First Article Signoff

If this feature is activated, the press will stop after the first board is completed, and will not continue until signoff
has been completed. Signoff is controlled by options set in the Press Data File. See the Press Data Editor below
for details.

Interrupting the Pressing Cycle

Releasing the two hand start switches will cause the press to stop immediately. Once the cycle is stopped,
pressing the buttons again will resume normal sequence where it left off. This makes it possible to slowly “jog”
the tool into the connector to closely observe the process. The “Z Up” on screen button can be pressed at any
time to bring the head up.

Changing the Pressing Sequence

The next connector to be pressed can be changed after a cycle has been interrupted. Using the mouse pointer or a
finger on the touch screen, highlight the connector to be pressed next, then press the “Go To” button at the bottom
of the screen. The sequence will start from the new point, and will automatically step to the next connector
according in the program.

Error Conditions Related to the Board, Connector, Tools, and Programs

Some of the common error conditions encountered during pressing are detailed below. Other error machine
related conditions are listed in the “Error Messages” section of this manual. The error conditions generated by the
Profile program are user defined so the wording may vary. In addition, new error messages not covered here may
be introduced in the future.
Premature Contact - This error is generated by the Profile program and is likely to be the most common error
condition that is encountered during normal operation. It occurs when the press head makes contact with the tool
before it should. The contact force and position thresholds are defined in the Profile for the connector. Here are
some of the possible causes:

20
The connector is tilted so it is sitting too high
The pressing tool is raised by a bent pin in the connector
The connector below the head is not the one expected by the program (the PCB is in the wrong position)
There is an error in the Press Profile program (*.prs) where the approach height is too low and causes the
head to hit the tool before expected
An incorrect board or backup thickness is called out in the Press Data File (*.pdf)
An incorrect tool height is called out in the tool database
The connector has a bent pin that is preventing it from entering the board

When this condition is encountered, the press head will rise to the board clearance position and display a message.
Careful inspection will usually reveal the problem. If the error is generated the first time a new program is run,
expect a position an error in one of the data files. In some cases it is OK to use the “Retry” option in case the
connector was tilted and the tool corrected the lean when it touched it. Use caution when retrying because if there
is a bent pin the retry may bend it over further and press it flat to the connector bottom.
Missing Connector - This error is generated by the Profile program. It will be obvious if a connector is missing.
Press “Stop/Eject” to bring the board out to replace the connector. If the connector is not missing there is an error
in the Profile program that must be corrected by the programmer.
Excess Force - This error is generated by the Profile program. It is displayed when the force required to seat the
connector exceeds the programmed limit. There may be a problem with the connector or PCB causing too much
resistance before the connector reaches its seated height. The fixture could be too thick causing the connector to
contact the PCB higher than expected. There may be a problem with the force or height definitions in the Profile
program.
Insufficient Force - This error is generated by the Profile program. It can be caused by a loose pin to hole
interference. It can also be caused by the platen being too thin, connector thickness problems, or Profile program
errors. The programmer should be consulted to correct the problem.

Runtime Help Screen:

This is the screen that can be brought up by pressing the F1 Key while in the 'Runtime mode' to assist in
Diagnostics of Profile performance. Also, this screen will indicate to you how to start the Data Collection mode
that creates a file defining 'point by point' performance within the press profile and logs this file to the SPC
Directory within the Press computer harddrive.

21
PRESSING TOOLS
This section defines general requirements for connector pressing tools that will be used in the manual press. In
most cases, insertion tools used in other manual pressing operations can be used in the electric press. The
guidelines below must be followed in order to ensure optimum performance.
Width – May be any width that adequately supports the pressing force
Height – There is 6” clearance from table to the full up pressing head. The tool, backup fixture, connector,
and board must be less than this measurement. The tool must be tall enough to avoid hitting any tall
components on the board.
Length - Up to 10” (to stay within the capture of the flat rock head), single or multiple tool combination
Laser Centering Option – An optional laser targeting spot can be used to align the tool below the center of
the pressing head.. The active laser pointer requires a reflective dot to be provided in a ½” diameter recess
on the top of the tool at the centroid. When the tool is properly positioned below the head, a signal is sent to
the computer. The green light in the front panel above the table lights when the tool is detected.

SUPPORT FIXTURES (Platens/ Backup Fixtures)

The support fixture, sometimes called a platen, must be a reasonably hard material. The flatness should be held to
a maximum deviation of .005” for best results. Most fixtures in use on other presses are adequate, but flatness is
often poor. Pressing to height will be a problem if the fixture is not flat.

PROGRAMMING & DATA ENTRY

The press is a highly versatile tool due to simple yet flexible programmability. Four databases are used to guide
the press through specific sequences of operations. The variables stored include pressing tool physical
information, pressing profile information, connector physical information, and PCB/ backup fixture information.
Once the information has been stored, it is available for use by current and future programs.
Access to the editors is restricted to those who have been trained and have the check box for our editor checked in
‘User Access’.

22
The Tool Editor

Purpose
The tool editor is used to view and modify the Microsoft Access Database information. It contains all the
necessary information about the mechanical pressing tools that are used during the pressing process. The editor
can be accessed either from the icon at the bottom of the screen, or from the supplied off line editor running on a
desktop PC. The following fields are maintained in the database and are saved immediately as they are changed
so there is no save operation on exiting.

Entries
“Tool Type” - This is a name you choose up to 20 characters long, spaces allowed, that will be used to refer to
this tool in the future. To enter a new tool type, click on “Edit” in the upper left of the screen, then select “Add
New Tool”. Alternatively, you can select “Copy Tool” to copy the currently viewed tool. You must enter a new
name. Selecting “Delete Tool” will delete the currently viewed tool entry.

“Bar Code” - This is the unique number that is used to identify the tool. It can be engraved and/or bar coded the
tool. It is convenient to use a bar code reader to confirm the tool type at run time.
Note: No two tools should ever have the same number except for interchangeable duplicates. In this case, only
one entry is made in the database.
“Enable Active Laser Target” – Select this checkbox if you are using the laser tool presence verification option.
See Pressing Tools section above for further explanation of this option.

23
“Dimensions”
Tool Clearance – This is the desired height of the pressing head above a tool that has been placed in/on the
connector. It is desirable to keep this to a minimum so the head can support the tool before pressing. It also aids
in detection of bent pins since the tool will not slide easily under the head if tool and connector are not both seated
properly.
Tool Height – The tool height information is needed in order to confirm the pressed height of the connector.
Enter the height of the tool from the top surface to the plane that presses on the connector as shown in the
graphic.
Tool Width – This entry is used to draw a rendering of the connector width in the PCB drawing on the screen.
Tool Length – This entry is used to draw a rendering of the connector length in the PCB drawing on the screen
“Comments” - Enter any comments desired such as a short description of the tool application.

24
The Connector Editor

Purpose
The Connector Editor is used to enter and store physical data for the connectors. It is an Access Data Base file.
All changes are saved immediately so there is no save operation on exiting.

Entries
“Connector Type” - This is a name you choose up to 20 characters long, spaces allowed, that will be used to
refer to this connector in the future. To enter a new tool type, click on “Edit” in the upper left of the screen, then
select “Add New Connector”. Alternatively, you can select “Copy Connector” to copy the currently viewed
connector. You must enter a new name. Selecting “Delete Connector” will delete the currently viewed
connector entry.
“Tool” - This is the type or name of the tool to be used for pressing the connector. It is picked from the tool data
base entries using the drop down menu. The tool must be entered in the tool database before the connector data
can be completed.
“Number of Pins” - This is the number of pins in the connector. It is used to calculate force when using max or
min force per pin in the profile. It is also used to calculate and graph the force per pin on the run time screen.
“Profile” - This is the name of the profile file to be used for the connector. It is picked from the profile data base
entries using the drop down menu. The profile must be completed before the connector database can be
generated.
“Dimensions” -
• Base Thickness - This is the thickness of the connector between the inside (mating section) bottom and the
outside bottom as shown. It is used to calculate the head travel to seat the connector to the proper height.
• Unseated Top – This is the measurement of the distance of the top surface of the connector to the top surface
of the PCB.

25
• Height – This is the measurement of distance from the top of the connector to the seating surface of the
connector. Subtracting ‘Unseated Top’ from ‘Height’ will give actual amount of distance left to press
connector to seated condition.
• Seated Height - This is the desired distance between the board surface and the bottom of the connector after
pressing. It is usually zero, but may be set above the board surface for press to height applications
“Graph Scale” – These entries control the graphing scale for the pressing process. The first is the vertical full
scale in pounds per pin, and the second is the horizontal scale in distance from the bottom of the connector to the
board surface.
“Force” -
• Min Force / Pin - This is the minimum acceptable force per pin. It is referenced in the pressing profile.
• Max Force / Pin - This is the maximum acceptable force per pin. It is referenced in the pressing profile.
• User Force / Pin - This is a user defined force per pin. It is referenced in the pressing profile.
• Other Force:
“PARS” – A connector can be pressed with force that is proportional to the actual resisting force detected during
the pressing cycle. This profile is controlled by the start and finish connector height and amount of % of force
applied over what is detected at end of cycle.
“Force Gradient” - Monitors the rate of change of force to distance. Generally, the force vs distance plot will
make a steep upturn as the connector contacts the board surface.. A minimum angle is specified for the upturn
which corresponds to how solidly the connector is pressed against the board. Enter the gradient angle at which you
want to complete the press cycle.

“Comments” - This is a field for useful comments.

.

26
The Profile Editor

Purpose
The pressing Profile is information that is used to control the pressing process speed, force, and height. It is the
heart of the control sequence, and allows the user to define exactly how a connector is pressed into the PCB. The
editor provides up to 20 steps, numbered at the left of the screen, to be entered for a given profile. Profiles are
stored as ASCII files with a user-specified name. The .prf extent is automatically added. They can be viewed in
any text editor.

Explanation
The insertion process starts at row 1, and proceeds from there. Each row has two “events”. “Height Above the
Board” and “Force”. As the press head travels down, the program continuously monitors these events and acts on
whichever occurs first. Each event has an “action”, which either continues the pressing process at another step
or generates an error. These events and actions are used to:
1. detect and announce unexpected contact
2. detect unacceptably high or low force generated during pressing
3. detect a missing connector condition
4. press to/verify the proper seated height
5. repress a connector that has already be partially pressed

There are four basic methods of pressing, and each requires a unique profile.

27
• FIXED FORCE PER PIN - A connector can be pressed with a force proportional to the number of pins, such
as 30 pounds per pin. This is slightly better than the first method because it recognizes that the force applied
should be proportional to the number of pins being pressed. It cannot compensate for normal variations in
required force per pin for different connectors, in different positions, in different boards.
• PERCENT ABOVE RANGE SAMPLE (PARS) – A connector can be pressed with force that is proportional
to the actual resisting force detected during the pressing cycle. This is called Percent Above Range Sample or
PARS. In this technique, the connector’s resisting force while pressing is sampled and averaged over a
distance Range before seating to the board surface. The final force exerted on the connector is limited to a
user-programmed Percent Above the Sample force. This percent added assures complete seating of the
connector. This is the most widely used technique because it limits the stress to the assembly and does not
require accurate board thickness measurement..
• PRESS TO HEIGHT – A connector can be pressed to within a programmed distance short of seating on the
board surface. This is the gentlest process possible because it exerts only enough force to press the pins into
the board. No excess force is pressed into the connector plastic or the board. This sophisticated technique is
made possible by the control available using an electric servo press head and a rigid press structure. In order
for press to height to be accurate, the board thickness must be precisely known. This can be done using the
thickness measurement probe and sequence provided.
• FORCE GRADIENT - Monitors the rate of change of force to distance. This method is used for robust
connectors that need to be seated against the board surface. Generally, the force vs distance plot will make a
steep upturn as the connector contacts the board surface. The connector stops moving so the force rises
quickly. A minimum angle is specified for the upturn which corresponds to how solidly the connector is
pressed against the board. See “Press Profile” for more detail.

The “standard” profile for each of the techniques above is provided with the press. They use variables whose
values come from the Connector and Tool databases rather than discrete numbers. Since each connector requires
the same basic steps, one profile with variables can be used for many different connectors.
The standard profiles are named “standard_force”, “standard_pars”, and “standard height”. The sample above is
the “standard_pars” profile.

Entries
“Height” - This defines the next destination of the pressing surface of the tool in inches above the board. The
press head will drive to this height at a speed that is linearly “ramped” from the height and speed of the previous
step.

The initial height (before step 1) is defined in the “Board Clearance” section of the “Press Data File”.
The available variables are shown here. Alternatively, a numeric height can be entered.
Height Action” - This defines the action to be taken when the height at this step is reached

Actions are selected from the drop down menu. The available actions are:

28
 Next Step - This directs the process to the next step below
Go To - This directs the process to continue at any step below. The step number is entered from the
keyboard
Complete - This signals that the pressing process is complete. The head will stop immediately and rise
to the next tool clearance height.
Error 1 - 5 - These are user defined error messages. If the height is reached and the action is an error.
The pressing process is immediately halted and the error message is displayed on the screen. The
operator must acknowledge the error message to continue.

“Force” - This defines the force which will trigger the force action. It is used for both

to detect force errors and define cycle completion based on the force generated. There are four variable choices
provided on the drop down menu. Alternatively, an actual force in pounds can be entered from the keyboard.
PARS-FPPL xx% (dynamic press cycle termination based on actual forces generated during the pressing
process) Pressing the PARS Help button will produce the picture below.

PARS-FPPL is defined as “Percent Above Range Sample - Force Per Pin Limited”. This force condition
uses a special algorithm that calculates the average force generated while pressing the connector into the
PCB. The “Start” and “Distance” boxes in the middle of the screen define the bounds for the average.
Thus, rather than pressing to a specific force, the actual force required is dynamically calculated for each
cycle and termination is based on this force. The “xx%” is an excess force, as a percentage of the
calculated average, which is added to the average to ensure the connector is fully seated.
For example: The “Start” height is entered as .010”, and the “Distance” as 0.005”. PARS-FPPL force is
invoked in the ‘Force (lbs)’column, row 4, and 25% is entered. As the connector is pressed, the force
readings taken from .010” to .005” above the board are averaged. The head continues to press until the
force generated is 25% higher than this average.
Min F/Pin * #Pins

This force is calculated by multiplying the number of pins in the particular connector being pressed by
the minimum required force per pin. Both the number of pins and the minimum force per pin are entries
in the connector data base. This can be used to assure at least a minimum force is generated during the
pressing process.

29
Max F/Pin * #Pins

This force is calculated by multiplying the number of pins in the particular connector being pressed by
the maximum allowable force per pin. Both the number of pins and the maximum force per pin are
entries in the connector data base. This can be used to prevent excessive force from being generated
during the pressing process.

User F/Pin * #Pins

This variable is provided for the flexibility of defining a force event variable other than Max and Min
force per pin. Its use is up to the programmer’s discretion. For example, while pressing to force it may
be useful to terminate on “User F/Pin * #Pins” rather than “Max F/Pin * #Pins”. The variable “Max
F/Pin * #Pins” would still be used to generate an error if the allowable force is exceeded.
Other Force
“ Force Action” - This defines the action to be taken when the force at this step is reached. Actions are selected
from the drop down menu. The force actions are the same as the height actions

.
Next Step - This directs the process to the next step below
Go To - This directs the process to continue at any step below. The step number is entered from the
keyboard
Complete - This signals that the pressing process is complete. The head will stop immediately and rise
to the next tool clearance height.
Error 1 - 5 - These are user defined error messages. If the height is reached and the action is an error.
The pressing process is immediately halted and the error message is displayed on the screen. The
operator must acknowledge the error message to continue.

“Speed (in/sec)” - This is the speed target for the current step in the process. The speed starts at

“Run Speed” as entered in the “Servo Parameters” editor, and changes (“ramps”) linearly down to the speed
given in step 1. When step 1 is reached, the speed ramps to the speed given in the next step processed. This will
generally be step 2, but not if a “Go To” was programmed as an action.
Typical speeds range from 2”/ second during approach, down to .05”/ second when pressing. Some experimenting
may be required to optimize the process. Some connectors are more fragile than others and may require slow
speeds, while others can be pressed quickly.
“Comments” - This entry is for your use as information and reminders. Typically each step has a purpose such as
“rapid to clearance above connector” or “slow down to enter connector and engage pins”, etc..
“Start” - This is the distance in inches between the board surface and the bottom (seating surface) of the

connector when PARS force readings are started. A typical number is 0.010”.

30
 “Distance” - This is the distance over which force readings are averaged for PARS use. A typical number is
0.005”. The shorter the distance, the fewer the number of points averaged. Look at the screen plot after the
connector is pressed (PARS information is overlaid on the graph) to be sure the average is being taken over the
correct range.
“PARS Help” - A text and graphic help screen is provided for PARS when this button is pressed.
“Action Errors” - Up to five errors can be defined here. They are used in the “Action” columns above. Typical
errors are “Premature Contact”, or “Excessive Force”, or “Missing Connector”.
Saving The File - Press “File”, “Save” or “Save As”, then “Exit”. If you press “Exit” before saving, you will be
warned and given the opportunity to save or quit without saving.

Examples
Example # 1– Pressing with PARS

The screen capture example above is a typical PARS press profile. The comments at the right end of each line
indicate the action that line will perform. In general, PARS pressing is the preferred method because it limits
excess pressing force but still presses the connector to the board surface. Fragile connectors that cannot accept
any excess force must be pressed to height as described in the example below.
1) Move the head from the tool clearance height (as given in the Tool Database) down to .03” above the
unseated top of tool. The speed will ramp linearly from the press “Run Speed” to .3 inches per second. When
the height is reached, the sequence will continue on the next step. If more than 50 pounds is detected before
the height is reached, terminate and display error #1, typically “Premature contact detected”.
2) Continue to move down to until the connector is .03” above its seated height. The speed is reduced to .
15”/second. This line tests to see if a connector is actually detected. If it is, as indicated by detecting at least
the minimum force per pin, the process continues on the next line. If not, the process continues on line 5.
3) Press until the connector is within .01” of the desired seated height. When this position is reached, the
connector will be within a generally accepted tolerance of seated height. The .01” can be adjusted as needed
for specific circumstances. If the force exceeds the maximum force per pin before the height is reached, an
error message is displayed.
4) The destination of this step will theoretically overpress the connector, but the process will actually be
complete as soon as the force reaches the PARS force plus 25%. The height given simply provides a
destination that is not intended to be reached because the force condition will be satisfied first. If the
destination is reached before the PARS force is reached, then there is most likely an error in the parameters
used to calculate the distance relationship between connector, tool, and board surface. If this occurs, review
the tool height, the connector base thickness, the backup fixture thickness, and the board thickness
5) This “GO TO” step tests to see if there is a connector below the head. If the normal seated height is reached
without generating at least 100 pounds of force, it is determined that the connector is missing. If the force is
reached, the process continues on the next line.
6) This line verifies the connector is pressed to within generally accepted height tolerance, and the maximum
force per pin is not exceeded.

31
7) This line gives a destination below the nominal seated height, and terminates on the maximum force per pin *
# of pins. This variable here could also be “user force per pin” rather then maximum.

A typical resulting screen plot is shown below. The PARS average force is given as 14.8 pounds per pin, or a
total of 7,548 pounds total. With 10% added to ensure seating, the force becomes 16.4 pounds per pin. Note the
average is taken between the vertical ‘PARS Sample’ lines.

32
The Press Data Editor

Purpose
The Press Data Editor is used to enter and store the data about the board including board physical characteristics
and connector locations. All connectors to be used on the board being programmed must be defined in the
connector database before the press data file can be generated.

The file is ASCII format with a .prs extent. It may be convenient to open an existing file and do a “Save As” to a
new name in some cases.

Entries
“Revision” - This is the revision level of the board to be pressed, or alternatively the revision of the Press Data
program. It is used as reference in this file only.
“Board Thickness” - This is the nominal board thickness which is used to calculate the connector pressed height.
If the board thickness measurement option is selected, the measured thickness will be used instead.
“Platen Thickness” - This is the thickness of the “platen” or “fixture” that supports the board on the top tool
press. It must be accurately measured in order for press to height to be accurate.
“Use Tool ID” – If this feature is checked a tool identification will be required on first entering the run screen,
and each time a tool change is encountered. The tool ID is the alphanumeric identification given in the tool
database. The ID can be entered manually, or by a bar code mounted on the tool.
“Description” - This is a description of the board to be pressed.

33
“No. of Char. Req’d for Serial Number” – The serial number of the board, if entered, is stored with the raw
pressing data in a file on the computer hard drive. If the connectors are pressed sequentially, the force for each
connector will be stored with the serial number and XY coordinates.
This feature has three types of entry. A zero means no prompt serial number will be given. A positive number
means exactly that number of characters is required for a valid serial number, and a negative number means at
least that number of characters is required. Bar code scanning is the preferred method of data entry.
“No. of Char. To Clear Between Boards” – This feature is used in conjunction with the serial number entry
above. In the case of sequential serial numbers, the program will clear this number of characters from the end of
the previous serial number. This is generally used when manual serial number entry is used.
“Verify Text” – This feature is intended to verify that the correct board type is used with its press data editor. If
text is entered in this cell, board identification (type, name, model, etc,) will be required on first entering the run
screen, and each time a new board is started. Any text or number can be used, but ideally a bar code label will be
available. The text can also be entered manually. To enter the name, type “%V” followed by the string of
characters.
“First Article Signoff” – This feature stops the pressing process after the first board is complete. An approval is
required from a different person than is operating the machine. The authorization level is established by selecting
one of the four dots below first article message text.
“Prompt for Connector Substitution” – This check box enables substitution connectors to be selected at run
time. For example, manufacturer “A” may be the prime source for a given connector, but “B” is also approved as
interchangeable on this board. If this box is checked, the operator will be offered a selection of possible alternates
for the connector at run time. Their selection will drive the tool and profile selected for pressing that connector.
Thus, it is possible to press an alternate connector that requires a different tool and different profile than the
primary connector. The alternates are associated with each other by “substitution codes” that are defined in the
connector database. The associated connectors are individually entered into the database, but they are “linked” by
a common substitution code. See the connector editor for details on entering connector substitution codes.
“Image Mode” – The user mode is defined as operator driven pressing sequence. In other words, the connectors
are pressed in any order the operator chooses. There are three options in the user mode.
 Digital Picture – This option uses a bitmap picture from a digital camera or scan of a photograph to show the
board being pressed.
 Data Image – This option creates an image from the X, Y, angle, and connector data and displays it.
 None – This option does not display an image on the screen. It has the advantage of the simplest to program,
but a press data file is still necessary to supply the operational information described above.
“Pressing Order” – The sequential mode provides a specific pressing sequence which must be followed. There
are two options in the sequential mode.
 Sequential – The pressing sequence is established by picking connectors from the database and placing them
on the digital picture in the desired order.
 Non-sequential – The pressing sequence follows the order of the data in the X, Y, angle, and connector table
below.

34
PRESS SEQUENCE
“Measure Board Thickness” - The check box calls for board thickness to be measured on each board. The X &
Y entries provide the location on the board for the thickness to be measured. Only one point on the board is
measured.
“Board thickness by Lot” - The check box calls for measuring board thickness only once for the current
manufacturer's board type within the present production run. A "Lot" is defined as a number of identical PCBs
used in a current production run.
“Board Edge to Reference Hole” - This entry is used by the program to properly locate and display the
connectors on the board. It is the nominal distance from edge of the board, in the X & Y directions, to the board’s
datum. The datum is the point on the board from which the X & Y locations (entered as explained below) for the
connectors are defined. In other words, it is the (0,0) for the array of connectors. The datum can be any
convenient point, and is usually either a tooling hole or the board edge.
Remember that the X direction is always defined as left to right with the board in normal orientation in the press.
“Reference Hole Board Frame Coordinate” - This is the distance from the datum (0,0) of the board which
locates the connectors (as explained immediately above) to the datum hole in the board. The datum hole mates
with a pin in the fixture (platen) which locates the board on the fixture. It is generally one of the board’s tooling
holes, but could be any hole chosen to physically locate the board.
“Board Width” - This is the dimension of the board in the X axis direction (left to right) as normally positioned
in the machine. It may or may not be the smaller board dimension.
“Board Length” - This is the dimension of the board in the Y axis direction (front to back) as normally
positioned in the machine. It may or may not be the larger board dimension.
“X,Y” - These entries define the position of the connector relative to the board’s coordinate system datum. Each
coordinate pair defines the location of the geometric center of the area that the pressing tool engages. This is
generally the centroid of the connector, but in some cases it is not.
“Angle” - This defines the angle of the connector relative to the board mounted on the machine. Select the
appropriate angle from the drop down menu. Angles are defined with zero degrees to the right. The positive 90
degree position is ¼ turn counter clockwise as viewed from the top. The connector “pointer” for angles is the
polarized end if defined.
“Connector” - The connector to be pressed is selected from the connector database by using the drop down
menu. All connectors to be used on the board must be defined in the connector database before the press data file
can be generated. The pressing sequence follows the order of the connectors entered here, so thought should be
given to optimize the movements. Connectors of one type should be pressed before proceeding to the next to
minimize tool changes.
“Comments” - User defined comment for future reference and reminder.

35
SPC OPTION
The SPC option is a software package of data collection, analyses, display, and printing.

Overview
Raw data for the average force in pounds per pin for each connector pressed is maintained in a file with the
same name as the connector, with a .RAW extension. SPC information is calculated from the raw data and
displayed on command.
Please refer to the “Connector Database” section above for SPC related parameters that are entered for each
connector type.
To view data for a connector, select the connector name from the drop down list in the upper left corner of the
SPC screen. All data on the SPC screen is for the specific connector type selected. The force data for a
connector is stored in the same file regardless of the specific PCB type (part number, model, etc.) it is pressed
into. In other words, the SPC data for a specific connector pressed into PCB type ABC is stored in the same file
as the data for connectors pressed into PCB type XYZ.
The raw data is stored on the hard drive indefinitely. It includes the PCB model, serial number (if used), date,
time, operator, the SPC force reading point, the maximum force read, and the maximum force reading point. The
header at the top of the raw data file explains the data format in detail.
An average force reading for each connector of a given type on a PCB is calculated and plotted as one point on
the X-bar chart. In other words, each point on the chart is the average of all connectors of the same type on a
specific PCB.
The difference between the highest and lowest force readings for the same connector type on a specific PCB is
plotted on the “R” (Range) chart. The “R” chart becomes an “S” (Standard Deviation) chart when the subgroups
size is greater than 5 connectors. The “S” chart plots the standard deviation of all connectors of the same type
on a specific PCB.

36
Process Data

This area shows data that is calculated for the process. It is a measure of the “health” of the process for a number
of PCBs.

CPK (Process Capability)

This quality measure is often used to evaluate the capability of the process being monitored. A number between
1 and 1.5 is generally considered to indicate a process is “in control”. The CPK is higher for a tighter and more
centered distribution, and conversely lower for a broad or poorly centered distribution. A distribution is
“centered” when the average of the measured data is near the target value for that data. A distribution is “tight”
when all measured values are close to each other.

X-Bar (Process Average)

This is the average of all the points on the X-bar chart. Each point on the chart is the average of a connector type
on a specific PCB.

Std Dev. (Standard Deviation)

This is the standard deviation (InterQuartile Range method ) of the plotted X-bar points.

UCL (Upper Control Limit)

If the plotted X-bar point exceeds this value, the process is considered out-of-control.

LCL (Lower Control Limit)

If the plotted X-bar point is less than this value, the process is considered out-of-control.

VCL (Variability Control Limit)

If the plotted variability point (R or S ) exceeds this value, the process is considered out of control.

Point Data

This area displays the data for a specific point. To view the data for any point on the chart, point to it and click
the left mouse button.

37
Options

Range Bars
The range for the data whose average forms a point on the X-bar chart can be displayed on the X-bar chart. It is
represented as a vertical line through the plotted point, with has a short horizontal line at the maximum and
minimum readings for the averaged data. Checking this box enables range displaying.

Control Limits
Checking this box enables the displaying of control limits on the charts.

Spec. Limits
Checking this box enables the displaying of specification limits (max and min force) on the charts.

Grid
This check box enables grid line display on the graphs.

Shaded
This adds shading between the spec limits and control limits.

Thick Lines
This thickens the plotted lines.

Print
Press this button to print the charts on a printer. The printer driver must be installed using the standard windows
method.

38
MAINTENANCE FUNCTIONS (UTILITIES)
The press software provides operational parameters and utilities as described below.

Machine Logs

Error Log
The error log is automatically appended with every error message that is displayed during any machine function.
This includes time and date stamp, operator, description , and duration of error condition. Cold startup is also
captured. By reviewing the log, machine operation can be evaluated on a detailed level. Data covering Selected
Dates can be viewed, or All can be chosen. Also see the Machine Utilization section for related data.
The error log can be purged by selecting the data period that you would like to save, then pressing Update Error
Log. For example, to delete all but the last 60 days of data, select “60 Days”, then press Update Error Log.

39
User Log
The user log is automatically appended every time there is a log in or out event. Data covering Selected Dates
can be viewed, or All can be chosen.
The user log can be purged by selecting the data period that you would like to save, then pressing Update User
Log. For example, to delete all but the last 60 days of data, select “60 Days”, then press Update User Log.

40
Joystick

The Joystick is used primarily for setup and maintenance purposes. Tabs at the top of the screen access utilities.
The right third of the screen is used to drive the servo axis.

Analog Inputs
The load cells provide a proportional analog signal of 0 to 10 volts over the full force range.

This screen shows the voltage and force numbers for each cell and the sum of the cells, as well as a bar graph
display. A small amount of “noise” (less than 1% of full scale) in the reading is normal. The balance between the
individual load cell readings should generally be within 10% of each other.

41
Points:
The points tab provides a robotic type of point saving capability. To add a new point , move

to the desired position then press “New Point”. Enter the name of the point and press “Save”. The new point will
be entered into the grid below.
Selecting any saved point from the grid will load the name and coordinates into the upper section of the screen.
Pressing “Move” will cause a move to the saved position. Pressing “Delete” will delete the point.
To change the coordinates of an existing point, move to the desired position, select the point to change, press “Set
Current”, then “Save”. The point’s coordinates will be changed.

Control
The “Control” tab is used to control the servo axis speed, turn it on or off, or set the maximum joystick

force limit. Both speed and force are at a default value on first entry into the joystick.
Enable / Disable Servo
To turn the servo axis off, press the “Disable” button. The indicator turns red. Press “Enable” and the servo turns
on and the indicator turns green. If the axis is off for any reason when entering this tab, the indicator will be red
already.
Speed
To change the joystick speed, drag the speed arrow to the right or left with the mouse. The current speed is shown
in the window below the speed slider.

42
Force Limit
The maximum press force while in the joystick is limited as a machine protection. The default limit is 25 pounds,
but it can be changed by dragging the slider. Attempting to press forces higher than the limit will result in an
error message.

Calibration
This tab is reserved for future implementation of an automatic load cell calibration procedure. Please refer to the
calibration procedure in the Maintenance section for the manual calibration procedure.

Tools
This tab is reserved for future tool related utilites.

Machine Zero
The Z axis zero is defined as the position where the head pressing surface is in contact with the table and loaded
to 300 pounds. The load is applied to be sure all clearance is eliminated from the various head components such
as the ball screw and the head to structure air gap.
Since the head cannot actually travel all the way to this point, a 2” spacer block must be placed between the head
and the table to set the zero. A tool is supplied with the press for this purpose. This same tool is also used for
PCB thickness measurement.
To set or verify the Zaxis zero position, place the space block on the table below the head. The head should be
positioned at the center of the machine. Go to the Control tab and reduce the speed to minimum. Also, set the
maximum joystick force to 350 – 500 lbs. Go to the Analog tab to get ready to read the load. Very carefully jog
the head down until it almost touches the spacer. At this point, change to incremental mode and move only in
increments of .001"” Apply load until 300 pounds is achieved.

WARNING! – Due to the machine’s high rigidity the force can build very quickly,
resulting in significant force overshoot if the Z axis is moving faster the minimum. Always
reduce the speed when approaching an object such as the thickness probe tool. Use
incremental mode @ 0.005” or 0.001” when pressing in the joystick.
When the load reaches 300 pounds +/- 50, read the Z axis position. It should read 2.000” (assuming the spacer
block is exactly 2” tall) +/- 0.002”. If there is an error, click on the machine zero tab and enter the known height
of the spacer block ( or thickness probe ). Then click the “Set Z” button to correct the machine’s position. This
will permanently modify the Z axis position. Although not required, it is a good idea to rehome and confirm the
zero position.

43
Input / Output Screen

Inputs
The Input/Output screen is provided for diagnostic purposes. All machine inputs are shown on the top half of the
screen. A red indicator signals an “on” condition for the given input. This screen is convenient for checking
sensor signals.
Outputs
The digital outputs are shown on the bottom half of the screen. Pressing a button will turn on the corresponding
output. A red button indicates the output is currently in the “on” state.

44
Servo Terminal

The Servo terminal is used to communicate with the servo controller card that resides in the PC. Various
information and data related to the servo card is displayed on the right half of the screen. Buttons below the
terminal window are provided for convenience. All parameters on this screen are continuously updated.
Servo Terminal Window
The servo terminal window is used to send low level commands to the servo controller. This feature will
normally be used only in conjunction with an ASG service technician advisor.

Warning: Be cautious when entering commands in this window since unexpected results,
including a major machine “crash” could result.
Buttons Below Terminal Window
Two help buttons below the window provide information on available commands. The “Erase Text” button clears
the screen. The servo can be turned on and off using two buttons below the window. The servo axis can be
homed by pressing the “Home” button.
ESTOP Indicator
The ESTOP indicator shows the status of the ESTOP circuit. If the circuit is energized (servo power is on), the
indicator will be red.
Position Data Windows
Windows on the right half of the screen show the position in inches and encoder counts, as well as position error
in encoder counts. The servo control command voltage is also shown.
Servo Status Indicators
The indicators show the status of several servo control signals.
ADC Input
The force on each load cell is shown in these windows. A one or two percent dithering is normal.

45
Servo Parameters

The Servo Parameters screen is used to input and display the servo related constants. These parameters should
only be changed by a qualified technician. Consultation with ASG is recommended before changing these
parameters.
Encoder Counts / in (PPU) – This is the conversion from encoder counts to inches. It is set at the factory and
should never have to be changed.
Proportional Gain – This control component provides the primary correcting voltage to the amplifier during
movement. The correcting voltage is proportional to the error between the actual and desired position, and the
gain modifies the correcting voltage.
Derivative Gain – This control component is a function of the rate of change (derivative) of position error.
Integral Gain – This control component is used only during the final position stage of a move. The correcting
voltage is a function of the position error integrated over time.
Integral Delay – The Integral Gain is turned on after the servo profiler reaches its destination. It is turned on
after this delay time in seconds.
Acceleration – This is the acceleration for all moves except during the pressing cycle. See Press Parameters for
Down Stroke.
Deceleration – This is the deceleration for all moves except during the pressing cycle. See Press Parameters for
Down Stroke.
Minimum Speed – This is the minimum speed that can be selected in the joystick.
Maximum Speed – This is the maximum speed that can be selected in the joystick.
Run Speed – This is the default speed used during the process. The Z axis speed used during pressing is
controlled by the profile.
Homing Speed – This is the speed used during the homing sequence.

46
Marker to Limit Distance – This is the physical distance the axis travels when moving from the marker pulse on
the encoder to the limit switch. It is used as verification that the homing sequence did not miss an index pulse on
the encoder. If the distance measured during homing does not match this number within a few thousandths of an
inch, an error is generated. The accuracy of the homing sequence is not dependent on this number. This number
will only have to be changed if the relationship between the encoder, which is mounted on the motor, and the head
is changed. This will happen if the motor is disconnected from the screw.
Marker to Zero Offset – This is the distance travel from the home pulse marker to the defined axis zero position.
It is the machine zero calibration point, and is set up at the factory. The zero position for the Z axis is defined as
the pressing flat rock surface in contact with the table surface. This position cannot actually be reached by the
axis. This number will only have to be changed if the relationship between the encoder, which is mounted on the
motor, and the head is changed. This will happen if the motor is disconnected from the screw.
Minimum Coordinate – This is the soft limit in the negative direction of travel. It is set up at the factory to be a
safe distance from the limit switch and the hard stop. This number will only have to be changed if the relationship
between the encoder, which is mounted on the motor, and the head is changed. This will happen if the motor is
disconnected from the screw.
Maximum Coordinate – This is the soft limit in the positive direction of travel. It is set up at the factory to be a
safe distance from the limit switch and the hard stop. This number will only have to be changed if the relationship
between the encoder, which is mounted on the motor, and the head is changed. This will happen if the motor is
disconnected from the screw.
Excess Error Limit – This is the maximum allowable error between the actual and desired position during
movement.
In Position Band –When the desired position plus or minus this distance (in inches) is reached, the In Position
Flag is set. When In Position is detected, the Integral Gain component is enabled.
Homing Torque Limit – This is the maximum torque (voltage) that the controller is allowed to issue during the
homing sequence. It is a machine protection feature that limits the runaway speed in case an encoder signal is lost
during homing.
Stall Detect Time – This is the allowed time in seconds (during an attempted move) that an axis can be stationary
before a stall condition is flagged. The axis is automatically disabled if a stall is detected.
Press Parameters
Down Stroke Acceleration & Deceleration – The machine default acceleration and deceleration are changed to
these values during the press down stroke. This allows more control flexibility during the pressing cycle.
Retract Speed and Acceleration - The machine default speed and acceleration are changed to these values
during the press retract stroke. This allows more control flexibility during the pressing cycle.

47
Setup Parameters

The Setup Parameters screen is used for miscellaneous parameter settings as described below.

Machine Operation
Threshold in SPC range for repress consideration
If the SPC force for a connector is less than this value, the connector is considered to have been repressed (the
connector has been partially repressed before). Repressed connectors are not used for SPC analysis as they would
“pollute” the data from their low forces in the SPC range.
Time Waiting For Two Hand Start
This is the time allowed before the machine utilization tracking changes from “Run” to “Idle”. If the next cycle is
initiated within this time, the utilization tracking remains in “Run” mode. The mode is changed from “Idle” to
“Run” as soon as the next cycle is started by pressing the two-hand buttons.
Number of Press Cycles
This is a non-resetable cumulative cycle counter. Each time a production pressing cycle is completed, this
counter is incremented.

Load Cells
The load cells measure the pressing force as each connector is seated. The force reading for each load cell will be
graphed if the check box is selected. Otherwise, only the total (sum) force is graphed.

48
Dynamic load cell zeroing is a feature that automatically eliminates any offset (difference from zero reading)
detected when no force is being applied. If checked, the offset updates before each pressing cycle.
Multiple readings from the load cells can be averaged before evaluating and graphing. This reduces the “noise”
that is present in typical analog signals. A setting of one will provide the fastest update, but could cause a false
reading if a noise spike is read as a real force. The larger this number is, the slower the response will be. A
setting of two is recommended.
The load cell readings are calibrated by entering gain and offset numbers for each rod load cell. The gain
converts the voltage from the load cell amplifier to pounds. The gain can only be set using an independent,
calibrated, load cell. Refer to the calibration section below for details. Offset is the load read when no force is
actually being applied to the head. Once calibrated, small deviations from zero can occur due to mechanical or
electrical changes. To set the offset, first enter “zero” in the offset window. Go to the joystick and read the
voltage shown for the rod you are working on. Enter the negative of this number in the appropriate window.
Recheck the joystick to be sure the force reading close to zero. Some dithering is normal.

Save
Pressing this button will save the changes and exit the screen.

Cancel
Pressing this button will cancel the changes and exit the screen.

49
Utilization

Machine utilization is tracked in four categories; Error, Idle, Run, and Off. The data can be displayed on the
screen as shown above, or printed in color or black and white. A check box in the lower right of the screen allows
the graph to show off time along with the other categories.

The period to display or print can be selected using the controls at the right side of the screen. To update the
graph for a new period, press the “Update Graph” button.

Printing charts is selected from the panel in the upper right of the screen. The standard printer setup dialog is
provided. The daily chart shows breakdown on an hourly basis, while the cumulative chart shows the distributions
as a pie chart.

50
PREVENTATIVE MAINTENANCE
The press has been designed to minimize maintenance as much as possible. The following preventive
maintenance procedures should be done on the intervals given below. An annual inspection, adjustment, and
calibration service is offered by ASG.

Accessing the Press Head

To gain access to the press head for inspection or service, the upper sheet metal panels must be removed using the
following procedure.
1) Remove the nine screws that secure the top cover to the front and back panels and set the cover aside.
2) Remove the four screws in the front panel and four screws in the back panel.
3) Lift out the front and back panels. Set them off to the side; reinstall in same order after completion of press
head service.

Cleaning
All surfaces should be kept clean and free of dust buildup. Wipe down all exposed flat surfaces with a soft rag.
If allowed use light air pressure to blow the press head and structure areas from the top down.

Inspection
Visually inspect the press head area. The top sheet metal housing should be removed once per year to allow a
thorough inspection. See procedure above for top housing removal.

Lubricating
Light machine oil or 30W non detergent motor oil should be used in the following areas of the machine:

Z Axis Rods
With the Z axis in the down position, put a small amount of oil on the rods above each of the linear guide
bushings. Wipe with a rag to coat the entire circumference of the shaft and leave only a thin film of oil.

Z Axis Screw
With the Z axis in the down position, put a small amount of oil on the screw and wipe down with a rag. There
should only be a thin coating of oil remaining.

Torquing Critical Bolts

Note: This procedure requires the top sheet metal housing to be removed. See the procedure above for details.

The critical bolts on the pressing head should be checked for proper torque. There are six high-grade 3/8-24
socket head cap screws mounting the top and bottom 1” thick steel plates. These screws should be tightened to 70
lb-ft.
On press serial numbers 1-4, the Z-axis bearing housing is mounted top of the 1” steel plate (on subsequent
presses the separate bearing housing has been eliminated). The block is secured with four 5/8 socket head cap
screws. The bearings are secured by a steel plate with four 3/8 socket head cap screws. These screws should be
tightened to 70 lb-ft.

51
Clean Water Trap In Air System
The air-inlet filter/ regulator set is in the rear cabinet. The power disconnect must be turned off to enter the
cabinet.
Check and drain water trap as needed. Replace air filter according to the schedule below.
PM Schedule

ITEM DAILY WEEKLY 3 MONTH YEARLY

BLOW MACHINE OFF *

WIPE MACHINE DOWN *
INSPECT WIRES AND HOSES *
OIL AS INDICATED ABOVE *
DRAIN WATER TRAP *
REPLACE AIR FILTER *
TORQUE HEAD BOLTS *
CALIBRATE Z-AXIS LOAD CELLS *
INSPECT BALL SCREW *

52
Load Cell Calibration

Calibration Procedure for Initial Setup of MEP-6T:

! CAUTION - This procedure requires access to 24VDC and exposed pinch points. It must
be carried out carefully by a trained technician.
Care must be taken to avoid personal or equipment damage. Proper safety equipment (ie.
safety glasses) should be worn at all times.
Pressing more than 10,000# force can only be done for a few seconds at a time to avoid
tripping the thermal overload circuit breaker, or entering and automatic amplifier power
fold back. If the thermal overload trips you must wait a few minutes for it to reset
automatically.
When applying force by moving the press head down, be very cautious not to overload or
impact the press head on the calibration load cell.

Purpose:
To perform initial (or as designated) Calibration of MEP-6T Press force accuracy from Zero to Full Span and
to document actual vs. acceptable measured points of Force along the Press’s range of pressure.
Equipment Required:

15K – 20K lb Calibrated Load Cell (National Bureau of Standards traceable)

Digital Readout for Calibrated Load Cell
Multimeter (Digital & Calibration Traceable)
Computer Workstation & Appropriate Calculation Spreadsheet program
Printer & AGS Calibration Record
3/4” Deep socket
3/8” Allen wrench

Procedure:

1. Turn MEP-6T on and observe safe process of bootup to ‘Ready for Operation’
2. Loosen Jam nuts and Load screws on top of each (2) of the Load Cells located in the Press Head.

Load Screw
& Jam Nut

Load Screw
& Jam Nut

Figure 1

3. Using Calibrated Digital VOM, perform Zero and Balance procedure on both TMO’s located on side of Press
head. See “Zero & Balance TMO Procedure.”

53
 4. Balance Load Cells. See “Balance Load Cell Procedure.”
5. Calibrate Load Cells. See “Calibrate Load Cell Procedure.”

Gain Pot

Terminal #3

Balance Pot

White Set Button

Terminal #4

Load Cell Amplifiers

Figure 2

Capture Screens for TMO Balance Procedure

Screen 1

54
 Screen 2
Zero and Balance TMO Procedures
Equipment needed:
Calibrated Digital Volt meter
Small screw driver
Zero Amplifiers
Note: Ref. Figure 2 for component layout of TMO Boards.
1) Remove the upper sheet metal panels.
2) Move the press head to the upper limit and to the right side.
3) Remove the cover over the load cell amplifiers. The cover is mounted on the left side of the press head.
4) Loosen the two bolts and jam nuts at the load cell housings above the Z axis rods. Back the jam nuts off
and turn each screw until it just touches the load cell. Without applying any load to the screws, turn the
jam nuts until they just touch the load cell housings.
5) Using a volt meter check the output of the load cell amplifier at screw terminals 3 & 4 on the left side.
Using the “BAL” Pot at the lower right, adjust the voltage to 0.00 +/- .01 Volts DC.
6) Press the white button at the lower right and hold while adjusting the “GAIN” Pot until the output voltage
is 3.50 +/- .01 Volts.
7) Readjust the zero volts as needed, and recheck the gain voltage.
8) Repeat for both amplifiers

55
Balance Load Cells Procedure:
1) Place the press head in the middle position.
2) Position the calibrated load cell below the press head.

Calibrated Load
Cell Figure 3

3) From the Joystick, select the “Analog Inputs” tab to view the load cell input. Verify that Forces for Rod
#1 and Rod #2 are at zero. Ref. Screen 1
4) Select the “Setup Parameters” button at the bottom of the screen. Ref. Screen 2. Press the ‘Zero Load
Cells’ Button
5) Temporarily, change the ‘number of force readings to average’ number from 2 to 20.
6) Press “Save”.
7) Go back to the “Setup Parameters” screen and note gains for Rod #1 and Rod #2.
8) Adjust the software Gain & Offset, as per the MEP & AEP Transducer Calibration Spreadsheet (Figure
4), by inputting numbers from step 7 into spreadsheet location E7 & E8.
9) Go to the “Control” tab of the Joystick and enable force of 10000#.
10) Slowly lower the Z axis until it is in light contact, then use the increment mode on the joystick at 0.001”
or 0.005” per move until 2000# is read on the digital display of the external load cell.
11) Balance the two load cells by adjusting the screws above them until each cell reads the same load. Keep
the total load at about 2000# by adjusting the screws tighter or looser as needed.
12) Raise the head until it clears the calibration load cell. If the load indication on the computer screen does
not return to zero, the screw(s) must be backed off until all force is removed, and the balancing process
must be repeated.
13) Continue to balance the cells until they are within 50# to 100# of each other at 2000# total, and
completely unloaded when the head is raised.

56
Calibrate load cell Procedure
1) Make sure the Load Cell screws snug up to the Load Cells and lock down the Jam nuts.
2) Lower the Z-axis until a load of about 5000#, “Actual Load”, is indicated on the calibration load cell
Digital readout.
3) Note the Total Force, “Indicated Load”, given in the Joystick Analog Inputs tab.
4) Note the “Rod Force #1”and “Rod Force #2”, given in the Joystick Analog Inputs tab
5) Note the Gain Values indicated in the Setup Parameters screen for Rod #1 and Rod #2
6) Using the spreadsheet tool: MEP & AEP Transducer Calibration file, input the values copied in steps 1, 3
&4
7) Reduce the load to less than 2000# by raising the Z axis
8) Go to the Setup Parameters tab and input the gain for both load cells according to the MEP & AEP
Transducer Calibration file: “New Gain Values”
9) Remove the load and be sure the indication returns to zero.
10) Reapply the load, check, and repeat as necessary.Check the calibration at loads from 1,000# , 2000#,
4000# and 8000 #. Do not maintain high force for
more than a few seconds. The indicated and actual should track within 200#. Each load cell should carry
about the same load throughout the test, but some variation is normal and acceptable.
11) Fill out Calibration Certificate (example shown on next page) as appropriate and as per figures generated
at bottom of Calibration Spreadsheet.

MEP & AEP Transducer Calibration Spreadsheet file

Figure 4

57
EXAMPLE

58
APPENDIX A - SPARE PARTS LIST
This is a comprehensive list of spare parts that may be required during the life of the press.
Any combination or quantity of the parts listed below may be purchased from ASG.
Delivery ranges from two to eight weeks depending on the part ordered. Please contact
ASG for the latest list and prices.

MEP-6T RECOMMENDED SPARE PARTS

Item Qty ASG Part # Manf. Part # Description
Req.
1 1 10110139 LBO-10K LOAD CELL - 10,000 LBS.
2 1 10110140 TMO-1 LOAD CELL AMPLIFIER
3 1 10110038 FS-L71 PHOTOELECTRIC SENSOR. LASER FIBER
AMPLIFIER
4 1 10110037 FS-L41 PHOTOELECTRIC SENSOR, LASER FIBER
5 1 10110381 SLS-24-024 24VDC POWER SUPPLY
6 1 10110029 SLD-12-3015-05 5 & 12 VDC POWER SUPPLY
7 1 10110072 OETL-NF30 40 AMP 3 POLE DISCONNECT SWITCH
8 1 10110064 S273-K16 16 AMP 3 POLE CIRCUIT BREAKER
9 1 10110065 S273-K10 10 AMP 3 POLE CIRCUIT BREAKER
10 1 10110066 S272-K4 4 AMP 2 POLE CIRCUIT BREAKER
11 1 10110067 S272-K8 8 AMP 2 POLE CIRCUIT BREAKER
12 1 10110068 KC622-Y 24 VDC OPER. CONTROL RELAY 20P 2 CL
13 1 10110069 T25DU14 10-14 AMP THERMAL OVERLOAD RELAY
14 1 10110070 AB25125A THERMAL OVERLOAD RELAY MOUNTING KIT
15 1 10110059 CBF-PMT4R-01 RED MUSHROOM E-STOP
16 2 10110219 CBK-B24 PILOT LIGHT BULBS
17 1 10110100 OTBVN6QD BANNER OPTO-TOUCH SWITCH
18 1 10110043 AAE-D204-M DPDT RELAY 8 PIN OCTAL RELAY
19 1 10110045 AAE-D304-M 3PDT 11 PIN RELAY
20 2 10110133 EE-SX670 PHOTOMICROSENSOR
21 2 10110136 EE-1006 CONNECTOR CABLE
22 1 10110147 DTR 90-015-H-348 15:1 PLANETARY GEARHEAD (RIGHT ANGLE)
23 1 10110021 H-348-H-0802 SERVO MOTOR
24 1 10110022 SE10000-1H348H SERVO AMPLIFIER
25 1 10110023 PA0800 SERVO MOTOR POWER SUPPLY
26 1 10110138 L BK 222800 MOTION CONTROLLER CARD
27 1 10110053 15975T12 REFLECTIVE TAPE
28 2 10110390 FNYBU24 SELF-LUBRICATED LINEAR BEARING 1 1/2w ID
29 1 10110149 6006 SINGLE ROW RADIAL BALL BEARING
30 1 10110151 6A30-C 1” x 20MM SINGLE FLEX COUPLINGS CLAMP & KEYED
31 1 10110142 CCFE-5/8-SB CAMROL BEARINGS ECCENTRIC
32 1 10110143 CCF-5/8-SB CAMROL BEARINGS CONCENTRIC
33 2 10110148 16054 UPPER & LOWER BEARING SEALS
34 2 10110150 7206WSU SINGLE ROW ANGLE BEARING
35 1 10110626 7824253 Z-AXIS BALL SCREW & NUT
36 1 10110538 PS-P2E-B EXTENDED PUSH BUTTON
37 1 10110085 MAV—3 MINIMATIC 3-WAY POPPET VALVE
38 1 10110025 NVZA2141-1-O1T AIR PILOT PNEUMATIC VALVE

59
APPENDIX B – FEATURES & SPECIFICATONS:
Features ~
• Pentium PC computer with Windows software
• SPC calculation, display, log & print - Option
-

• Touch screen monitor - Option

• On-line setup drawings and photographs
• Operator log in & out
• Error log with date, time, & operator information saved to
disk
• Maintenance & setup software utilities
• Graphic display of board in process
• Force-Vs-distance on screen graphs
• Software controlled pressing profile with error detection
and user defined messages
• Electric servo pressing (Z axis)
• Support table with brass surface for static grounding
• High rigidity 2 large Z axis guide rods with linear
-

bearings
• Press to force
• PCB thickness measurement and press to height
• Missing connector detection
• No oil, no air in oil problems
• Clean & Quiet
• Energy efficient

Specifications ~
• Force-6 tons
• Force sensitivity 15 lbs
-

• Z axis travel = 5”
• Z axis speed = 2” in/sec
• Power: 220 VAC, 3 Phase, 15 A
• Dimensions: 56” Wide X 36” Deep X 70” High
• Weight: Approximately 1500 lbs.

Options ~
Option
SPO Package
Board Thickness Measurement
Touch Screen Monitor

Updates ~
Call (561)848-6746 for information on how to obtain the latest
version of MEP-6T Software.

60
APPENDIX C – MAJOR COMPONENT LAYOUT / DESCRIPTION:
MEP-6T HARDWARE

Main Frame Assembly:

1. MEP-6T Main Frame (structure).

• The Main frame, also referred to as the structure, is the center or heart of the MEP-6T.
• All accuracy’s and precessions are originated from this main frame (structure).
• It consists of a Tubular Frame, Tabletop, Side Posts (2 ea.), Top Side Plates (2 ea.), and
Bottom Side Plates (2 ea.).
• 4 Casters utilized for ease of machine mobility.

61
 Top Side Plate

Table Top

Side Post

Bottom Side Plate

Press Frame

MEP-6T
Frame Assy.

62
 MEP-6T HARDWARE
Floating Head Assembly:

1. MEP-6T Floating Head Assembly.

• Utilizes a floating air bearing technique to float the Head Assembly.
• Used for side to side placement of the Head Assembly over the connector to press.

2. Z-Axis Motor.
• Located top of Head Assembly.
• Controls the Z-Axis (up and down) movement of the press assembly.
• Used to generatc the necessary torque required to properly press the connectors onto the
circuit boards.

3. Z-Axis Gearbox.
• Located between the Z-Axis motor and the Z-Axis Baliscrew.
• Used with and in conjunction with the Z-Axis motor to generate the forces required to
press connectors to circuit boards.

4. Z-Axis Motor Encoder.

• Located on the back of the Z-Axis Motor.
• An optical encoder type unit, which provides the necessary feedback for proper location
of press tooling and speeds, associated with the pressing operations.

5. Z-Axis Ballscrew.
• Located approximately at the center of the press head assembly.
• Proves Z-Axis motion (up & down), which generates the actual forces necessary for the
pressing operation.

6. Press Head Posts, 2 ea.

• Transfers pressing forces through the Guide Rod Bearings to the Press Hcad Base and
Press Plate Tooling Head (Anvil).

7. 10K(10,000lb) Load Cells, 2 ea.

• Located near middle of Head Assembly.
• One 10k load cell for each press rod.
• Provides press force feedback (analog) to the TMO amplifiers.

8. TMO Amplifiers, 2ea.

• Located on top left side of Press Head Assembly.
• One amplifier for each load cell used.
• Used to provide an amplified, analog feedback signal (from load cells), to the computer.
For load cell forces used in data processing arid for readouts on the computer screen.

63
 MEP-6T HARDWARE

Floating Head Assembly:

9. Laser Light.
• Located between Guide Rod Bushings, attached to Laser Light Mount.
• Used to help operator center Connector Press Tooling over connector to be pressed.

10. Laser Light Controller.

• Located top left side of Press Head Assembly.
• Controller for the Laser Light.
• Can be programmed and adjusted for laser light sensitivity.

11. Upper and Lower Limits.

• Used to set the upper and lower limits of the Press Head Assembly.
• Used to keep press from hitting or crashing either into baliscrew assembly or table.
 Z-Axis Motor Encoder

Z-Axis Motor

Z-Axis
Encoder
Z-Axis Gearbox

Z-Axis Ball
Screw

Upper Limit Flag

TMO
Amplifiers

Upper Limit Sensor

TMO Covers

Lower Limit Flag

10K Load Cell

Laser Light Mount

Guide Rod Bearings

Pressing Plate
Tooling Head Press Head Posts
Press Head Base
(Anvil)

MET-6T
Head Assy.

65
 MEP-6T
Sheet Metal

66
MEP-6T Monitor
Stand Assy

67
APPENDIX D - ELECTRICAL / MECHANICAL SCHEMATICS

68